Custom 1.6mm Thick Aluminum Carpc Trunk Case

**LiquidKernel** · 06-12-2006, 03:24 AM

Seeing as I didn't want to buy a pre-made case, I decided to make my own. I bought a 48" x 15" sheet of 1.6mm thick aluminum on eBay for around $20 shipped. I then bought a bending brake on eBay for another $20. Bringing the total to a mere $40.

Using a Dewalt 18V Jigsaw and BOSCH metal cutting blades, I cut out my sheet into the size I needed. Then bent in in particular places with the bending brake.

Here is the outcome... so far I have mounted everything solid (mobo, HD and PSU) and made all the openings I need (minus ventelation). The top and sides will be another piece which will screw into two side beams.

I also realized that my case is the same size as my stock CD changer, so I'll just mount it in the trunk using the little ears on the sides of the case.

Everything in place, rear of the case.

Connections.

PSU mounting.

Screws holding in the hard drive.

Side beam, I will make it shorter (in height) for airflow to the fans. The top will screw into it.

Proposed placement of my 40mm fans.

You can see more progress pics in my worklog thread here: 1995 Volvo 850 T5 -- 2 din install

Let me know what you guys think!

**LiquidKernel** · 06-12-2006, 03:27 AM

Another note.. I'm thinking spraying it with black Plastidip to make it more rugged?

**seanshine** · 06-12-2006, 10:55 AM

Nice work on those bends there.As far as spraying the case,I'd leave it raw as you'll get better heat dissipation.While I'm looking at it,do you think a
40 mm fan will move enough air to keep things cool?

**BarryWoods** · 06-12-2006, 11:47 AM

Originally Posted by seanshine

Nice work on those bends there.As far as spraying the case,I'd leave it raw as you'll get better heat dissipation.While I'm looking at it,do you think a
40 mm fan will move enough air to keep things cool?

Works in servers. Though they have a few more of them.

**LiquidKernel** · 06-12-2006, 03:13 PM

Originally Posted by BarryWoods

Works in servers. Though they have a few more of them.

I'll try two for now, slits on one side and two exhaust fans on the other.

**LiquidKernel** · 06-12-2006, 03:22 PM

Originally Posted by seanshine

Nice work on those bends there.As far as spraying the case,I'd leave it raw as you'll get better heat dissipation.While I'm looking at it,do you think a
40 mm fan will move enough air to keep things cool?

Thanks. Bending the large portions were hard. It maxed out my bending brake.

Agree with heat dissipation being better without paint.. might just leave it like that. But then might paint it with high-temp flat black ceramic paint.

**mach5** · 06-15-2006, 01:48 AM

Originally Posted by LiquidKernel

Thanks. Bending the large portions were hard. It maxed out my bending brake.

Agree with heat dissipation being better without paint.. might just leave it like that. But then might paint it with high-temp flat black ceramic paint.

One thing I've always wondered if high-temp heats dissipate heat better or insulate the heat better? Based on your statement, I'd assume the former.

Like I said, always wondered. heh.

**VW_Carputer** · 06-15-2006, 07:52 AM

thats a preaty cool looking case

**Peoples** · 06-15-2006, 08:04 AM

i would spray it with bedliner paint, but not plastic dip.....i tried doing this to my mound for my LCD once.....its too difficult to get even

**damarble** · 06-15-2006, 03:28 PM

Originally Posted by Peoples

i would spray it with bedliner paint, but not plastic dip.....

Agreed. I used the Plastidip on a G5 mouse I modified, it was not durable at all and got blisters after a couple weeks. After they popped the stuff peeled off.